Method and apparatus for reducing occupant injury in frontal collisions

ABSTRACT

A safety restraint system comprising a safety belt system for restraining an occupant comprising safety belt; a retractor for protracting and retracting the safety belt, a shoulder belt support for supporting the shoulder belt portion of the safety belt; a pretensioner for providing, subsequent to activation, a preload tensile force in the shoulder belt portion in excess of a first low limit value of about 50 pounds; a load limiter for limiting the loads imparted by the shoulder belt portion to an occupant, operative after the preload acts on the shoulder belt portion, including first means for introducing a predetermined amount of slack in the shoulder belt when the belt tension is above a second low limit value and for preventing such slack introduction when belt tension is lower than such second low limit value.

This application is a continuation of application Ser. No. 08/502,345, filed Jul. 14, 1995, now abandoned which is a continuation of Ser. No. 08/286,069 filed Aug. 4, 1994 (abandoned).

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to occupant restraint systems and more particularly to an integrated restraint system which is designed to significantly improve occupant safety.

Safety belt restraint system (or sub-systems) and sir bag systems (or sub-systems) are often designed to meet separate and distinct safety criteria and performance standards and then used together as a combined system to provide occupant protection during frontal vehicle crashes and accidents. The performance, in terms of known, measurable occupant injury performance standards such as head injury criteria (HIC) and resultant chest acceleration of these combined systems may be less than the performance of the individual sub-system. This is shown below. It is believed that the degradation in performance, as manifested by increased occupant chest acceleration and related chest loading, is the result of an effective increased stiffness afforded by the seat belt system working in concert with the air bag system.

It is an object of the present invention to provide an improved occupant protection system. The invention herein describes a method and apparatus for improving occupant performance in frontal accidents in comparison to the state of the art. The present invention proposes integrating in a single belted restraint system a very high output seat belt pretensioner 38 with an energy absorbing load limiting device 30. As will be seen from the description below the invention provides a surprising improvement to occupant protection as measured by performance standards such as HIC and chest acceleration. The benefit afforded by the present invention can be further enhanced by the addition of a web clamping device (such as a web clamping refractor) and/or the use of a low elongation webbing, that is a webbing having an elongation of less than eight percent (8%). High output pretensioning as used herein refers to any pretensioning or belt tightening device which after operation provides a residual belt force (belt tension) of fifty pounds force or more. Such high output pretensioning device, according to the present invention, may include the buckle type of pretensioner in which the sea belt buckle is linearly moved or a retractor pretensioner in which the spool of the retractor is reverse wound. The concept of high output pretensioning is not available in current products and as described below results in the very early interaction of the seat belt with the occupant and provides a significant early acting restraining force, against the occupant, during the accident or crash event. Reference is made to curve 300 FIG. 1 which shows the results of a physical test of a simulated prior art combined system verifying the benefits of the present invention. Curve 300 shows the resultant chest acceleration imparted to an occupant as a result of combining a prior art seat belt sub-system with air bag subsystem. As can be seen the peak accelerative occupant loading is about 56 g's. FIG. 2 is a bar graph showing the test results (chest acceleration) for a 30 mph simulated barrier crash of: a) the prior art seat belt sub-system (1), b) the prior art air bag system each tested alone (2), c) the combined seat beat and air bag performance (3) and d) the performance (3) of the integrated systems in accordance with the present invention. FIG. 3 shows comparable data showing the HIC performance criteria. From the summary data shown in FIGS. 2 and 3 it can be seen that the peak accelerative loading and head injury criteria of the combined conventional system (g=56) exceeds that of either sub-system (g=45,41 ), this deficiency is avoided in the present invention. The results of the integrated system show that a chest acceleration (g) of 27 is attainable. Similar improvements in the HIC performance standards can also be seen in FIG. 3.

The deficiencies in the prior art, combined system can be seen from the following. During the first few milli-seconds following a crash the occupant is protected only by the seat belt system as the air bag has not yet deployed sufficiently to contact the occupant. The protective restraining forces generated by the safety belt system (or sub-system) are highly dependent on the amount of permitted occupant movement, or excursion, which is strongly dependent on the geometric placement of the seat belt system components such as the anchor points, the shoulder belt D-ring (or belt guide as it is often called) and on the amount of belt slack that exists prior to the collision as well as the inherent force deflection properties of the particular seat belt system such as the elongation of the belt and deflection characteristics of a padded seat. The net result is that the restraint force is applied to the occupant late in the collision event and such force is very uneven (i.e. includes high peaks) as can be seen for example curve 300 of FIG. 1. Conventional seat belt pretensioners or belt tighteners, as they are also known, of either the buckle type or retractor type offset, to some degree, the effects of occupant excursion by eliminating some of the slack that may exist in the seat belt. As is known in the art, a conventional, low output pretensioner attempts the belt system prior to any forward movement by the occupant which action typically occurs during the first ten (10) to twenty (20) milli-seconds after the beginning of the collision. As known in the art such pretensioners do not produce high residual forces in the seat belt. This conclusion comes directly from the way pretensioner are tested and proven in actual practice. A typical test of a pretensioner includes wrapping a test dummy with a soft foam the thickness of which stimulates a certain amount of slack that would exist in actual driving conditions. The forces developed during the operation of current pretensioners are generally only sufficiently to eliminate the slack (i.e. to compress the foam) prior to the time that any significant loads are developed in the seat belt or pretensioner due to the forward motion of the occupant. The low output pretensioner effectively manages occupant energy by providing a more uniform seat belt load application, thereby somewhat reducing the intensity of occupant or belt loading. However, the deficiency of the prior art pretensioner in that belt loads can increase the concentrated nature of the loading on the chest and as a result high chest deflections still occur. Other deficiencies with the prior art pretensioner are they do not generate a sufficient amount of residual force to effective manage occupant energy to control post crash movement of the occupant. While the pretensioner usually limits the forward velocity of the occupant it also inherently reduces the mount of permitted movement of the occupant. As such the occupant is not permitted to controllably move into the inflating air bag to permit more of the restraint load to be shared by the air bag.

Another effective means for enhancing occupant performance with a belted restraint is to use a load limiter. Load limiters effectively clip or limit peak loads that normally occur in the belt system by reintroducing a certain mount of slack in the seat belt system sometime after the accident has begun. The true benefit provided by a load limiter is in relation to combined seat belt and air bag performance which is to reduce the resultant restraint force imparted to the occupant. The load limited seat belt has the advantages of restraining the occupant's torso before it is contacted by the air bag. The load limited seat belt subsystem assists in mitigating the additive loading nature of the seat belt and air bag systems. A conventional load limited belt system may result in a reduction of chest acceleration of about 10%, depending on the specific application, see curve 304 of FIG. 4. As load limiting systems reintroduce slack into the belt, excursions are typically higher compared to a more conventional belt system,

High output pretensioning devices, in accordance with the present invention, can lower chest accelerations by at least 20% due to the smoother lead application. Such devices are most effective, however, when used in combination with a high energy absorbing load limiting device which may be integrated within the same device or incorporated separately. Without the high output pretensioner, it is difficult to transmit lead to the load limiting device early in the accident event thereby limiting energy absorption to also occur early in the accident event. This early onset of load and energy absorption is critical to developing the pseudo constant acceleration process in the occupant response, which is felt to be near ideal.

Energy absorption or lead limiting changes the characteristic of the seat belt, primarily the shoulder harness, by changing the force-deflection properties, usually resulting in a plateau or a nearly constant force device/system. The load limiter maintains restraint forces on the occupant which do not result in high accelerations or chest deflection, Further, the energy absorption mechanism can be tuned for optimal performance in a variety of environments. The strain rate sensitivity of an energy absorbing device can offset significantly severe impacts or help larger occupants by providing a greater restraint force during high energy occurrences. Further, the energy absorbing device can be tuned to a specific vehicle crash pulse to give the optimum shape to the lead profile in the belt. For example, the energy absorbing device can be made stiff to correspond with high accelerations in the vehicle pulse and less stiff during low acceleration periods in order to achieve a pseudo constant acceleration in the occupant response. Limiting lowers chest accelerations about 10-30% when compared to a conventional restraint system. When the proper energy absorbing device is combined with a high output pretensioner, occupant injury criteria can be reduced by 50% or more.

The true benefit of the integrated, present system is marked reductions in occupant injury response (HIC, chest accelerations, femur loads, chest deflection, neck response etc.). The absolute ideal occupant response to vehicle deceleration could be achieved by restraining the upper torso from an initial speed to a final speed in a linear fashion with the torso and head stopping just short of the instrument panel thereby avoiding interior contact. This constant acceleration process results in the lowest possible accelerations. Further, it is desirable to decelerate the head in the same manner in unison with the torso thereby causing low head injury criteria (HIC) and low neck injury. A system simultaneously utilizing high output pretensioning and load limiting is aimed at approximating this ideal situation in the following manner:

In accordance with the present invention the high output pretensioner applies a residual force in the belt of at least fifty pounds. This results in very early application of restraining force and control of the occupant velocity build-up with respect to the vehicle interior. The resultant chest acceleration shows (see curve 302 of FIG. 1) the effect of the high output pretensioner by increasing early in the event when compared to the normal case. Hip excursions are also reduced leading to very low femur loads. The ideal constant acceleration case is shown by phantom line 306. FIG. 5, curve shows a time trace showing the performance attainable with both a high output pretensioner and a load limiter.

Further in the present invention the load limiting device becomes activated at 350 lb-2000 lb dynamically. The load limiter can operate in this range at a constant force level or any force profile tuned to the particular environment within these ranges although it may go out of these ranges at times. The load limiter provides a plateau in the chest resultant acceleration by providing the means for a somewhat constant restraint force and therefore somewhat constant occupant accelerations (see FIG. 5). These accelerations are well below the typical accelerations for a conventional system and approach the ideal acceleration case. The same improvement for head injury criteria is shown in see FIG. 3 results in low neck injury. Because the energy absorbing device is used in combination with a high output pretensioner, very low occupant injury (low performance injury test data) is observed with occupant excursions that are comparable or below those measured with a typical seat belt system. The load limiter may also offer reduced resistance to occupant load at a time when the airbag system begins to offer significant restraint. The load limiter may also offer increasing restraint when significant occupant excursion has occurred and it is evident when the occupant is large or the crash is quite severe. Also, the load limiter may be passively or actively adjust to these various test conditions to offer optimal resistance.

The combined and tuned system may be further enhanced by the addition of a web locking device to increase the initial stiffness of the system and ensure rapid onset of restraint force. The same effect can also be observed by the use of low elongation webbing which will also stiffen the system (see curve 308 of FIG. 6).

The early restraint of the chest followed by load limiting results in low accelerations in the chest and a better introduction of the occupant into the bag. That is, the head and torso are in unison as they engage the airbag at which time the restraint force of the bag controls both body parts. The net result is an improvement in both head injury criteria and neck response (not shown).

Many other objects and purposes of the invention will be clear from the following detailed description of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 shows time traces of resultant chest acceleration for various test conditions.

FIG. 2 is a bar graph summarizing chest acceleration.

FIG. 3 is a bar graph summarizing HIC (head injury criteria).

FIG. 4 shows results using a low load limiting feature to a combined system.

FIG. 5 shows improved system performance with combined a high output pretensioner and load limiter.

FIG. 6 shows improved response with the inclusion of a web locking or clamping retractor as well as a high output pretensioner and load limiter.

FIG. 7 illustrates a typical vehicle with a safety restraint system.

FIG. 8 shows a preferred embodiment of a high output pretensioner.

FIG. 9 is an isolated view of a part of the pretensioner.

FIG. 10 shows a force-time graph.

FIGS. 11-16 show a new load limiting device in accordance with the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

Reference is made to FIG. 7 which diagrammatically illustrates a conventional three point seat belt and air bag system generally shown as 20. The system 20 includes a safety belt 22 comprising a shoulder belt 24 and a lap belt 26 which are retracted and protracted by a retractor generally shown as 30. The shoulder belt is supported by a webbing or belt support 32 such as a web guide or D-ring. The shoulder belt 24 and lap belt 26 are slidingly joined through a tongue 34 that is received within a buckle 36 located proximate a seat 29. As illustrated, the buckle is attached to a buckle pretensioner 38. Positioned in the steering wheel 25 is an air bag 27, shown deployed.

As mentioned carrier, it is an object of the present invention to provide a system having seat bolt pretensioner which after activation provides a residual belt force in excess of fifty pounds (222 N). One such buckle pretensioner 38 is shown in greater detail in FIG. 8. As illustrated, the pretensioner includes a housing 40 secured at one end to a bracket 42 and at its other end to a tube 44. More specifically, the housing includes a central, stepped bore 46 having a narrow first portion 48 and a wider central portion 50 which communicates with a stepped bore 52. One end, such as 54 of the tube is pressed fit or otherwise secured to the housing 40 at the step bore 52.

The bracket 42 includes a pin or shaft 60 and a bushing 62. Rotatably positioned on the bushing is a pulley-like, cam lock mechanism 70. The cam lock 70 includes two parallel facing walls 72a and 72b and a center reel portion 74 that my be concave shaped, as shown. The spacing "s" between the walls 72a and 72b is slightly greater than the diameter of a cable 76 connected to the buckle 36 to permit the cable to move therebetween. The cable is shown in phantom line in FIG. 9.

Reference is again to FIG. 8. As can be seen, cable 76 extends from the buckle and is threaded about the rear of the cam lock 70 about the reel portion 74 and then through an opening 48' at the bore portion 48 and into the tube 44. An end, such as 80 of the cable is secured to a movable piston 82 by known mechanical means including a clamp, weld or an adhesive bond generally shown as 84. The piston 82 is slidable within the inner wall 86 of the tube. The piston 82 includes a piston housing 90 one end of which supports a seal such as an O-ring 92.

Returning momentarily to the bracket 42, such bracket includes two outwardly extending ribs 94a and 94b, positioned 90 degrees apart, which in combination with the cam lock 70 provide a channel to capture or guide the cable as it is threaded about the cam lock. While not shown in the figures, the bracket 42 would be connected to a mounting bracket which may be attached to a vehicle seat or to the vehicle floor.

As can be seen from FIG. 8, the housing 40 supports a pyrotechnic element generally shown as 100. Such pyrotechnic elements are known in the an and are responsive to an electrical signal received at one or both of the electric terminals 102a and 102b. Upon activation of the pyrotechnic element 100, products of combustion are generated which increase the pressure within the center bore. This increased pressure bares upon the left hand end 83 of the piston 82 urging same to the right. As the piston moves to the right, it pulls the cable 76 about the cam lock 70 thereby lowering the height of the buckle relative to the vehicle seat or floor removing a predetermined amount of slack in one or both belts 24 and 26. Reference is briefly made to FIG. 10 which is illustrative of the force-time profile of the load generated in the belt upon activation of the pretensioner. This force/load is the tensile force generated in the torso and shoulder belts 26 and 24 connected to the buckle as little as 10 milliseconds after the firing of the pyrotechnic element 100. In the steady state it is anticipated that the residual preload force greater than the desired fifty pound (222 N) limit, in this case about 100 lbs.

An optional second pyrotechnic element 110 may be fined in the center bore of the pretensioner 38 which functions to provides additional force application to the piston over an extended time period. As shown this pyrotechnic element is hollow having a center core 112 through which the cable 76 slides. Upon ignition of the first pyrotechnic element 100, its products of combustion ignite the second pyrotechnic element 110 which in turn generate further products of combustion to increase the pressure applied to the piston 82.

The piston 82 is designed to complete its stroke prior to either of the shoulder or torso belt being loaded by the occupant as a result of a crash Once these belts are loaded by the occupant, an outwardly directed force, generally shown as 114 is exerted on the buckle which will tend to move the buckle and cable 76 outwardly from the housing 40 opposite to the direction of the piston stroke. To prevent this reverse motion and to maintain the residual load, the cam lock 70 includes a lateral cam wall or cam surface 75 which extends across the side walls 72a and 72b, and which rotates with the cam lock, in a clock wise manner as the buckle is extended or pulled from the housing. The cam lock 70 rotates because of the fictional engagement with the cable 76. Upon rotation of the cam surface or member 75, the cable 76 is locked in place as it is pinched by the member 75, preventing further the extension of the buckle 36 and cable 76. To increase the fictional interaction between the cable and the cam lock, the reel 74 may optionally include a knurled, i.e. uneven or unsmooth, surface 77. The cam lock 70 is biased by a bias spring 79 the purpose of which is to prevent the cam lock cam or surface 75 from becoming jammed as the cable is moved to the right which in turn attempts to rotate the cam lock counter clockwise. The spring rotates the cam lock to maintain a given amount of surface contact between the cable and the cam lock 70. As can be appreciated from the above, the pyrotechnic forces are primarily concentrated within the housing 40, as such the tube 44 need not absorb any of the pressure forces generated upon activation of the pyrotechnic elements 100 and 110. Consequently, the tube may be fabricated of a thin walled aluminum tubing. The end of the tube 44 is closed by a pin or cap 45.

Reference is made to FIGS. 11-16 which illustrate an emergency locking retractor 30 capable of achieving the energy absorption characterizes described above. The retractor 30 includes many components found in conventional retractors such as a U-shaped frame 150 having side walls 150a and 150b. Rotationally supportal within the side or side walls 150a and 150b is a spool generally shown as 152. In the present invention, this spool 152 comprises a center core 154 having at its ends a center hubs 156a and 156b (see FIG. 12). In the embodiment shown a solid shaft 158 is used, however, other type sharks may be employed such as a split core shaft. The shaft 158 includes end parts 158a and 158b received within slits 159a and 159b of each center hub 156a and 156b. The shaft is secured to each center hub using a metal forming technique. Secured about each center hub 156a,b is a ring gear 162a and 162b respectively. Each ring gear includes a plurality of locking teeth 164 formed on its periphery. The ring gear 162 is shown in isolation in FIG. 13, in cross-section in FIG. 14 and in combination with one of the hubs in FIG. 15. The outer edge 200 of each center hub and an inner edge of each the ring gear 162, are secured together by a controlled fit, such as an interference fit generally shown as 166 which under normal operating conditions, permits the center hub 156 and ting gear 162 to rotate as a unified part. In additional, each ring gear 162a,b includes an inward radial extension 202 which provides added support for a side 204 of the hub. The hub is pressed against the extension 202. The purpose of this extension 202 will be described below.

The webbing 20 is secured to the core 154 of the spool 152 in a known manner. Spaced from each ring gear is a dual locking member generally shown as 170 having pawls 172a and 172b joined by a center shaft 174 (see FIG. 11). As can be appreciated the center shaft permits the pawls to be moved in unison. Such locking members are not shown in great detail as similar acting devices are known in the art. In normal operation, the pawls 172a and 172b are spaced from the teeth 164 of each ring gear 162. During an emergency or crash situation, a sensor such as a vehicle sensor 180 itself having a movable pawl or mass, of known type moves the pawls 172a and b into locking engagement with each ring gear.

Retractor 30, as does most if not all retractors, additionally includes a rewind spring 182 and may also include a web sensing mechanism. This web sensing mechanism is shown diagrammatically, and is mechanically coupled to move the locking member 170. Such web sensors are known in the art. As an example one such web sensor my include a clutch member which is used to move a movable plate which in turn moves the locking member by interaction with an extending pin (not shown).

During an accident, and in response to the movement of one or the other of the web or vehicle sensor, the locking member 170 moves the pawls 172a and 172b into locking engagement with the teeth 164 of the ring gear to prohibit further rotation of the spool 152. The pretensioner 38 of the present invention is typically activated prior to or at least at the same time as the vehicle sensor begins to lock the retractor. Also, when the pretensioner 36 is activated it initiates the removal of a predetermined amount of slack webbing from the system and generates a defined residual load in the webbing at an amount that is greater than 50 lbs. (222 N). The above actions happen prior to or during the early moments when the occupant begins to move forward due to the decelerative forces imparted to the vehicle by the crash. Subsequent to the operation of the pretensioner, and as a result of the crash forces, the occupant moves forward, and engages the safety belts 20 and in particular the shoulder belt 24. As the occupant presses on the shoulder belt, forces are directed via the web guide or D-ring 32 and to the locked retractor. Reference is made to FIG. 16 which show the force generated in the safety belt as the function of web extension with the retractor 30 locked. The first part of this graph shown as 320 is characterized by a relatively steep slope which is defined primarily by the elongation of the webbing. In a typically safety belt the elongation is about 8 percent. The slope of the curve will remain generally constant until the force imparted to the spool 152, the center hub 156 and ring gear 162 exceeds a predetermined lower limit (in this case about 500 lbs) defined by the force necessary to overcome the interference fit between the center hubs 156 and the ring gears 162. Upon exceeding this force which is set to correspond to the desired force absorbing range such as 350 lbs (1557 N) (up to about 2000 lbs), the center hub 156 beings to slip and to rotate relative to the locked ring gear 162. As can be seen the force-time graph, at this time will achieve a generally flat slope. The value of the retarding forces generated during this time are basically limited by the slippage forces necessary to maintain the center hub 156 and ring gear 162 rotating relative to one another. Subsequently, as the relative rotation between the center hub 156 and ring gear 162 increases heat is generated causing, in on embodiment of the invention, these two components to friction welded together. In the present invention the ring gear and hub can be designed to weld together or remain friction loaded together after slippage has occurred. A benefit of permitting the ring gear and hub to be reattached or sufficiently loaded together is that even after the system has initially protected the occupant, that is during a first accident event and because the ring gears and hub are again physically joined by welding or physically frictionally coupled the spool and webbing will be able to be retracted by the rewind spring and the spool again can be locked in the event of a secondary impacts. The slope of the last section 324 of the curve is generally defined by the residual elongation of the webbing. By residual elongation it is meant the elongation remaining in the webbing after the initial accident. It is envisioned that the elongation of the webbing may change somewhat after it is stretched. In an embodiment where the parts remain friction loaded after slippage, the slope of the last part of the graph will be more horizontal as shown or at least correspond to the friction forces between the ring gears and hubs.

Many changes and modifications in the above described embodiment of the invention can, of course, be carried out without departing from the scope thereof. Accordingly, that scope is intended to be limited only by the scope of the appended claims. 

I claim:
 1. A safety restraint system comprising:belt system means for restraining an occupant comprising: a safety belt; retractor means for protracting and retracting the safety belt; shoulder belt support means for supporting the should belt portion of the safety belt; pretensioner means for providing subsequent to activation, a residual preload force in the safety belt in excess of a first low limit value; load limiting means for limiting the loads imparted by the shoulder belt portion to an occupant, operative after the preload acts on the shoulder belt portion, including first means for introducing a predetermined amount of slack in the shoulder belt when the belt tension is above a second low limit value and for preventing such slack introduction when belt tension is lower than such low limit value.
 2. The device as defined in claim 1 wherein the second low limit value equal to or greater than 350 pounds.
 3. The device as defined in claim 1 wherein the first low limit value is greater than about 50 pounds.
 4. The device as defined in claim 1 wherein the second low limit value is in a range of 350 to 2000 pounds.
 5. The device as defined in claim 1 wherein the first low limit value is in a range of 50 to 400 pounds.
 6. The device as defined in claim 1 including an air bag and mean for inflating the air bag including an electronic sensing subsystem means for generating at least one control signal and inflator meals for providing inflation gas to the air bag in response to the at least one control signal.
 7. A method of protecting an occupant in a safety system comprising a seal belt, a high output pretensioner operatively coupled to the seat belt and a load limiting device for permitting occupant motion, the method comprising the steps of:
 1. sensing an accident2. operating the pretensioning device to provide a residual preload in the belt in excess of about 50 pounds,
 3. permitting the load limiting device to absorb crash loads introduced on the occupant when such loads are in excess of about 350 pounds.
 8. A safety restraint system comprising:belt system means for restraining an occupant comprising: a safety belt; retractor means for protracting and retracting the safety belt; shoulder belt support means for supporting the should belt portion of the safety belt; pretensioner means for providing subsequent to activation, a residual preload force in the safety belt in excess of a first low limit; load limiting means for limiting the loads imparted by the shoulder belt portion to an occupant, operative after the preload acts on the shoulder belt portion, including first means for introducing a predetermined amount of slack in the shoulder belt when the belt tension is above the first low limit value and for preventing such slack introduction when belt tension is lower than such low limit value.
 9. The device as defined in claim 1 wherein the first low limit value equal to or greater than 50 pounds. 